BRPI0614705A2 - composition, hybrid rock, process for converting waste material into a hybrid rock, and, hybrid rock apparatus - Google Patents

Abstract

COMPOSITION, HYBRID ROCK, PROCESS TO CONVERT RESIDUAL MATERIAL TO A HYBRID ROCK, AND APPLIANCE TO FORM HYBRID ROCK. The invention relates to synthetic hybrid rock compositions, manufacturing articles and related processes that employ mineral waste starting materials, such as mine tailings, mine rock, ash, slag, quarry fines and sludge, to produce valuable articles of manufacture and products, which are characterized by superior physical and structural characteristics, including low porosity, low absorption, greater resistance and durability, and retained plasticity. The resulting materials are compositionally and chemically distinct from conventional synthetic rock materials, as demonstrated by scanning electron microprobe analysis, and are used in a wide variety of applications, particularly with regard to commercial and residential construction.

Description

COMPOSITION, HYBRID ROCK, PROCESS FOR RESIDUAL CONVERTER MATERIAL ON A HYBRID ROCK, AND APPLIANCE FORMING A HYBRID ROCK "

FIELD OF INVENTION

The following invention is generally directed to synthesized hybrid material rock compositions, articles of manufacture and related processes which employ as starting material mine tailings, mine rock, ash, slag, quarry fines, slime and similar mineral waste materials. DESCRIPTION OF RELATED TECHNIQUE

Processing of degraded area by mining and residual demineral, so far, are not unprecedented industries. There are numerous systems, processes and methods for performing environmental mining clean-up, and for manufacturing useful products from raw materials that are basically made up of waste mineral constituents.

US 3,870,535 discloses a method of treating coal mine waste to produce cementitious material which is self-hardening at atmospheric pressure and can be used as structural filler, road base material or alternatively as a consolidated aggregate barrier to prevent percolation penetration and resulting surface water contamination. The method involves treating coal mining tailings from coal extraction processes with limestone (to neutralize sulfuric acid), or limestone and a pozzolanic material, such as fly gray, to react at atmospheric pressure for at least several days in the presence of moisture. with sulfate ions that have been released from the tailings and, in some cases, also react with waste soluble iron products. The claimed products are coal mine tailings mixtures and stoichiometrically distinct concentrations of limestone, water and ash. The products of the invention are generally of the variety 3CaO, Al2O3.3CaSO4, 30-32H20 or 3CaO, Al2O3, CaSO4 and 10-12H20. Permeability test data for product samples indicated that permeability decreased after the completion of a seven day curing period at 100 ° F (37.8 ° C). Similarly, compressive stress data indicated that compressive strength of the material, measured in PSI, increased with increasing cure time. Detailed information regarding the density and plasticity of the composition is not disclosed. However, the composition is cementitious in nature, and therefore of limited application and potential utility. Well-known disadvantages associated with cement-based products include high porosity and structural instability due to temperature and climate fluctuations.

U.S. Patent 5,286,427 discloses a method of performing environmental cleaning by producing structural construction materials using mine tailings material. The method involves providing facilities for producing the structural building material; providing raw materials for producing the building material, raw materials comprising unprocessed mine tailings (with a grade of material suitable for immediate use) as a substitute for processed silica sand, but aluminum dust cement; analyze mine tailings to determine the composition by weight percentages of other present raw materials, prepare a sludge from the mine tailings and combine the sludge with other raw materials to form a concentrated sludge; adjusting the quantities of other raw materials according to the weight percentages determined in the mine tailings; and processing the concentrated sludge through the provided facility, including a final curing step that produces the structural building material. Because of the chemical reaction that occurs in the release stage, the production slurry changes from a fluid form to an almost solid form of the building material. The almost solid shape expands and fits into the shape of a mold and facilitates cutting into smaller curing units. The autoclaved aerated cement, produced and claimed, is limited in its ability because the composition lacks plasticity and is therefore incapable of subsequent efficient reforming. Information regarding the required permeability, porosity and cure time of the material is not disclosed. As stated earlier, well-known disadvantages associated with cement include high porosity and structural instability due to temperature and climate fluctuations.

U.S. Patent 6,825,139 discloses a crystalline composition, a polycrystalline product, an article of manufacture and a related process using carbon ash as a starting material. The process involves mixing carbon ash particles with at least one glass-forming agent and at least one crystallization catalyst, melting this combination to form a mixture and cooling the resulting mixture to room temperature to form a non-porous homogeneous polycrystalline product comprising SiO 2, Al 2 O, CaO, Fe2O3, TiO2, MgO, Na2O, Li2O, CeO2, ZrO2, K2O, P2O5, Cr2O3, ZnO and MnO2. Polycrystalline products are polycrystalline materials obtained from glassware compositions by catalytic crystallization and consisting of one to several crystalline mineral phases evenly distributed over the remaining glass phase. The microstructure evaluation, revealed by electron microscopy, showed a dense glass-ceramic structure with crystal dimensions of approximately 1 micron. The mineralogical composition of the composition, demonstrated by X-ray diffraction, revealed that the predominant crystalline phase is amortite, while the additional crystalline phases include lithium disite and lithium disilicate. The glass density was determined at 2,720kg / m; porosity less than 0.02%; and the bending voltage was up to 150MPa. However, the composition is heated to temperatures that require the addition of at least one crystallization catalyst to perform the various crystalline phases, and to the extent that the composition, article and corresponding process are relatively labor intensive and prone to inaccuracy if errors occur during catalyst addition. .

Volume processing of relatively homogeneous mining mineral material has also resulted in the creation of numerous ceramic tile products of varying quality and durability. For example, conventional ceramics produced by the processing of mixtures of natural mineral constituents and mixtures may be classified according to their glass content as non-glassy, semi-glassy and glassy. Non-glassy ceramic, of which Dal-Tile is an example, is generally made of clay, talc and carbonate minerals, and has a water absorption greater than 7%. Flux minerals such as feldspar are not used in these compositions. Non-vitreous Dal-Tile of this type has a water absorption of 13-14% as measured by ASTM C373. This type of tile has virtually no glass content, and achieves its structural integrity from solid state reactions and sintering. Semi-glass ceramics, of which Balmor is an example, generally have a certain glass content and corresponding water absorption of between about 4% and about 7%. This is a red body product, its color because of its natural iron content. Such bodies are generally made of clay-containing earth mixtures containing quartz and natural feldspar. The latter acts as a fluxing agent to produce a liquid phase during firing, said liquid phase converting the cooling into glazing. Glass ceramic, including porcelain tile, of which Granitifiandre Kashimir White is an example, has less than 4% water absorption. True porcelain products typically have water absorption values of less than about 0.5%. These materials are basically made from raw materials of kaolinite clay, quartz and feldspar. They have a high glass content (typically 20-30%), and are also characterized by the lack of crystalline phases that precipitated from the liquid phase during cooling. They usually contain mullite mineral (3ΑΙ2Ο3 - 2S1O2) formed at high burning temperatures from the solid state composition of the kaolinite raw material.

Commercially Available Non-Glazed Ceramic / Tile Materials

Figure 1 is a backscattered electronic image (BSE) of the non-vitreous commercial ceramic tile scanning electron probe manufactured by Dal-Tile ™. This BSE image illustrates the typical mineralogical microstructure of this unglazed ceramic tile by discrete flocculated particles (1 and 2) that are cemented (sintered) without apparent glass matrix. Dispersive Energy X-ray (EDX) chemistry spectra of the dominant flocculated particles show a chemical composition of magnesium silicate. This composition corresponds to the mineral "enstatite" (Mg0-Si02) identified in the X-ray diffraction analysis (XRD) performed on this deazulejo / ceramic tile sample. The enstatite mineral phase does not "grow" or crystallize a liquid phase as none exists but instead is formed as a high temperature pseudo-amorphous solid state replacement mineral for a largelyoriginal talc feedstock. . Talc is a hydrous magnesium silicate mineral Mg 3 Si 4 O 10 (OH) 2.

Light (white) reaction edges (3) surround voids (black), some of which contain partially dissolved particles (4).

EDX analysis indicates that edges (3) have a magnesium aluminum desilicate chemical composition that corresponds to the cordierite mineral (MgO-Al2O3-S1O2) detected by XRD analysis. Partially dissolved particles in the center of some voids have a typical periclase magnesium oxide chemical composition. The abundance of this MgO material was too low to be detectable in XRD analysis.

Secondary angular particles (5) with a silica chemical composition correspond to the quartz (Si02) composition detected as a secondary component in this ceramic tile by XRD analysis.

The abundant (black) voids illustrate the high vapority of this non-vitreous ceramic tile (6). The absence of significant glass matrix in this material causes little grain deletion contract in the matrix (7). Both of these physical properties contribute to higher water absorption, lower hardness and lower modulus of rupture (MOR - a measure of mechanical strength) determined for this ceramic tile.

Commercially Available Semi-Glass Ceramic Tile / Tile Materials

Figure 2 is a retrodispersal electronic image (BSE) of the Balmor ™ semi-vitreous commercial electronic scanning tile. Figure 2 illustrates the typical mineralogical microstructure of this semi-vitreous ceramic tile of partially or completely dissolved primary mineral grains. EDX analyzes of these demineral grains revealed the chemical compositions, which are correlated with specific minerals identified by XRD analysis as constituents of this tile / tile material. These include potassium feldspar (10), feldspatoplagioclase (11, quartz (12) and goethite (Fe (OH) 2) (13).

These primary mineral grains are cemented by a semi-continuous amorphous glass matrix. The EDX microchemical analysis of two areas of glass matrix (14 and 15) shows that the particular ratios of cations K, Na and Ca in the two glass areas appear to be similar to the two adjacent feldspar compositions (compare 10 with 14 and 11 with 15). This similarity indicates that glass compositions may vary with respect to the composition of cations, and are affected by the specific cation constituents within the adjacent mineral grains that fuse or dissolve to form the glass matrix material. Figure 2 reveals that the glass matrix of this tile Semi-glassy ceramic tile is semi-continuous, resulting in a moderate degree of retained porosity 16. This porosity is largely disconnected, but not completely, resulting in lower water absorption properties. Primary grains are not completely bonded (17) in the glass matrix, which causes a reduction in material durability and hardness.

Figure 2 also does not show secondary crystallite minerals in the vitreous matrix. No evidence is indicated that new crystalline mineral phases precipitated from the liquid phase during the cooling process. Commercially available vitreous ceramic tiles

Figure 3 is the retrodispersal electronic image (BSE) of the scanning electron probe of the vitreous ceramic tileGranitifiandre Kashmir White. This BSE image illustrates the typical microstructural structure of this vitreous ceramic tile composed of partially dissolved primary grain debris. The EDX microchemical analysis of some of these grains correlates with the XRD analysis to confirm that the mineralogy of this tile is dominated by quartz (20), plagioclase feldspar (21) and zirconium (22).

Figure 3 shows that quartz grain outlines show evidence of significant dissolution (20), whereas feldspar grains are fused or dissolved severely to completely (21). The secondary zirconium grains were evidently a mixture to achieve the fused texture on the porcelain tile (surface22) body. The vitreous matrix appears to be continuous, leaving only a few voids or isolated pores and producing low water absorption properties (23).

Figure 3 also shows no apparent crystalline minerals in the vitreous matrix and suggests that no such secondary minerals were formed from the liquid phase. However, mullite - a mineral formed by solid state transformation - was identified in the XRD analysis. Due to its typical acicular crystalline form and very small department size, its presence in this ceramic was not positively identified in the BSE analysis. The total atomic weight (density) of the mullite may be quite similar to that of the glass matrix, making it indistinct from glass.

As discussed above, inefficiencies involving conventional methods of processing residual minerals such as mine tailings and the structural and compositional limitations inherent in conventional ceramic products - particularly with regard to corresponding water porosity and absorption, lower hardness and low modulus of rupture - demonstrate that there is a double need for (1) an effective and efficient strategy to stop mineral tailings such as low cost mine tailings and high safety; and (2) a low cost and easily manufactured non-clay glassy synthetic rock material having superior and even collectively unavailable characteristics, including low porosity; impermeability in vitrification; high plasticity for subsequent sterilization; and altar resistance and durability. The disclosed invention addresses these double needs simultaneously.

BACKGROUND OF THE INVENTION

Efforts towards mine tailings and mining degraded area have evoked enormous environmental concerns inside and outside the United States. Tailings are waste products that remain in wastewater-containing areas after the metals have been extracted from a particular location, and consist primarily of residual rock containing a variety of rock-forming minerals, including major constituent groups crystalline silica, feldspar and clay minerals. with secondary constituent groups including carbonates, sulfates, sulfide micas. Pollution problems associated with mine tailings related to structural integrity and stability of tailings containment areas and potential impacts should containment fail. At the heart of these concerns is the potential pollution of mine and surface water tailings, and correspondingly how such potential pollution affects people living in the immediate vicinity of waste containment areas.

The need for effective demining degraded area strategies and safe disposal of potentially hazardous mine waste is equally widely recognized in the demining and environmental industries. There is no doubt according to the laws that the safe disposal of mine tailings, as opposed to continually attempting to contain them, is desirable from both an environmental and economic safety point of view. Similarly, other mineral waste materials similarly raise concerns for environmental contamination, and the need for their safe and effective disposal is also widely recognized.

Already in ancient Mesopotamia, researchers located what they believe to be basaltic rock plates formed of silica-clay debris. Inhabitants are believed to have used basaltic rock as a major component in the region for a variety of purposes, including ceramics, architecture, writing materials, technical objects, and tools.

In simulated studies to recreate basaltic rock from silica-clay debris, researchers were able to approximate the composition and texture of basaltic rock by using local alluvial silica-clay debris as a departmental material, and by heating the material within a temperature range defined by a period of prolonged time. The resulting basaltic rock was characterized by combined clinopyroxene crystals embedded in a vitreous matrix, with both starting material remains rarely appearing completely absent from the final basaltic rock. Basaltic rock was more likely to be of limited strength as it did not have an aggregate microstructure. Because of the observed presence of many large pores, some up to 3 mm, basalt had high water absorption, probably well over 7%.

In more recent examples of waste materials, ash and ash from coal-burning debris for electricity are very non-combustible waste formed from inorganic minerals carbon. Approximately hundreds of millions of tons are produced each year in the United States alone. Fly ash and debris ash are also produced in waste incinerators and biomass power plants. Slag mineral waste materials result from metal-processing operations. Digging and dredging operations often produce silicate waste materials such as fines or sludge that must be disposed of safely.

Relatively pure mineral materials (kaolinite clay, feldspar, quartz, talc, etc.) have conventionally been used to fabricate a variety of ceramic materials with varying quality eg compositions. As previously described, Dal-Tilen glassy tile, Balmor Tile semi-glassy and Granitifiandre Kashmir White glass represent some of them. However, these and a vast array of other conventional ceramic products (ceramic tile, dinnerware, etc.) are typically manufactured by methods that are based on the plasticity and bonding (in the unburnt state) of clay - generally kolinite - and generally use relatively pure raw materials. As previously stated, conventional ceramics also demonstrate numerous undesirable characteristics, including moderate to high porosity and water absorption, low hardness and strength, and the absence of secondary crystallite formation upon cooling, which contributes to product durability. Also, in the manufacture of conventional ceramics, considerable concern is placed on the quality and purity of the raw material ingredients. Additionally, contaminants in the raw materials can cause considerable damage to conventional product quality in terms of structural integrity and defects in cosmetic properties. Surprisingly, the process and composition of the applicant is tolerant to higher concentrations of many materials that are considered contamination in conventional ceramic fabrication. . Such materials include iron, magnesium, manganese, sulfur and their compounds.

There is a need in the environmental clean-up industry to develop an effective and efficient strategy for mine recovery, mine tailings disposal after the mining of mineral in the mine has finished, mine rock disposal, ash disposal, and ash disposal. power plants or incinerators, slag disposal and disposal of silica-clay fines or debris. There is an equally significant need in the synthetic rock industry to produce an easily absorbed, low-porosity low-absorption glass tile in a relatively inexpensive and relatively quick manner.

SUMMARY OF THE INVENTION

Applicant's invention provides a crystalline and glass composition derived from the processing of raw mine tailings and similar waste materials that can be used to create valuable fabrication articles and products for a wide variety of uses, particularly, but not limited to, the construction industry. commercial and residential, for example, such as floor, wall, tiles, bricks, blocks, exterior cladding, panels, tiles, countertops, road base aggregates and other construction materials. The exclusive composition comprises a phase, a glass phase and a crystalline phase. Said clast phase is additionally comprised of mineral grains, mineraloid grains, glass beads, or rock fragments, and any of which may have been partially fused, or partially dissolved, or partially transformed by chemical reaction. Said glass phase provides a matrix that is cemented together with the clasts. The crystalline phase is completely obscured by the glass phase which has been formed by growth from the liquid phase. The unique single-phase glass-fused clast composition, which further comprises a newly formed crystalline phase, is characterized by a microscopic aggregate (synthetic rock / glass matrix) structure with superior structural physical characteristics including low porosity, low absorption, increased strength and durability, plasticity retention to facilitate subsequent sterilization for initial processing, and easily discernible chemical attributes, compared to conventional synthetic rock materials, demonstrated by scanning electron probe analysis.

The glass phase (glass matrix) is created as a result of the partial fusion of a suite of original raw mineral constituents, which may include feldspar, quartz and mineral materials found in a wide range of rock types, and which may additionally be present as individual mineral grains. (monomineralic) or as derocha fragments (polyimineralic). After an ideal melting period, the resulting glass matrix is cooled for an optimal cooling period and during cooling period exclusive silicate and non-silicate minerals varying proportions of iron, magnesium, calcium and sulfur crystallize from the liquid phase to form small crystallites distributed throughout the matrix. Importantly, newly formed secondary crystallites include silicate, tectosilicate and sulfate compounds that are not present in the starting material, and are not found in commercially available ceramics in the same way. Occasionally, some of these minerals may be found in commercially available ceramics; however, these minerals are not secondary crystallites formed from a molten phase, but instead are remnants of the starting raw material. The specific minerals formed in the applicant's ceramic materials are affected by the unique chemical composition of the waste mineral feedstock materials such as tailings, ash, etc.

Inosilicates are single chain and double chain silicate minerals. The pyroxene group of inosilicates comprises single chain non-hydrated ferromagnesian decanter silicates. The amphibole group of inosilicates comprises double decade hydrated ferromagnesian chain silicates. Wollastonite is a calcium silicate mineral in the group silicate.

Tectosilicates are silicate minerals of structure, including minerals such as quartz and the feldspar group. Plagioclase feldspar is a solid solution series of feldspar minerals with varying amounts of sodium and calcium.

Sulfate minerals are a group of sulfur-containing minerals. Gypsum and anhydride are calcium sulfates, with anhydride forming the dehydrated form and plaster the hydrated form.

Pyroxenes, particularly enstatite and hyperstene (the iron-containing version of enstatite), as well as augite, diopside, bronzite and pigeonite, are not conventionally present in starting materials and have not been detected in semi-vitreous or porcelain ceramics. Instead, pyroxenes were detected by X-ray diffraction analysis (XRD) and scanning electron probe (microsphere) analysis using a high porosity scattered energy X-ray spectrometer (EDS) only. , such as the non-vitreous ceramic Dal-Tilesupradiscussed. However, probe analysis reveals that these non-glass ceramic pyroxenes have a morphology that indicates to those skilled in the art that they are the result of solid state chemical reactions rather than crystallization from a fused phase. In contrast, amphiboles, particularly in the form of hornblende, were detected in raw rock material from mines but not in processed material because these compounds did not survive high temperature processing due to dehydration and bond degradation during the heating process.

Wollastonite and plagioclase are common ingredients of some conventional non-glass ceramics to achieve specific types and properties of ceramics. However, wollastonite and plagioclionion have not been detected using microwave probe analysis and EDS techniques as a newly crystallized phase in conventional ceramics, instead they appear as sintered primary mineral grains.

Anhydrite and / or plaster are not conventionally present in starting materials and were not detected in conventional non-glassy, semi-glassy or glassy ceramics.

Applicants' compositions and articles comprise both original tailings as well as newly formed mineral phases, which make them compositionally distinct not only from the mine tailings product but more importantly from conventional synthetic shell compositions and articles. corresponding manufacturing A key compositional distinction between the starting raw material, compositions and articles of the applicant, and conventional synthetic rock compositions is the presence or absence of inosilicate minerals, specifically pyroxenes, wollastonite, tectosilicates, specifically plagioclase feldspar, esulfates, specifically anhydrite. As set forth in more detail below, the applicant's compositions and articles contain pyroxene, newly formed plagioclase inosilicates, wollastonite and anhydrite, which have hitherto not been detected in low porous glassy synthetic rock materials. Specific pyroxene materials that can form in this rock Synthetic may include, but are not limited to, one or more of the following: augite, diopside, hyperstene, pigeonite, bronzite, and enstatite.

Moreover, the applicant's invention employs a unique heating and cooling strategy that completely eliminates the need for the addition of recrystallization catalysts.

That is, heating the raw material to a temperature at which part, if not all, of the raw material components begins to melt at least partially. At these temperatures, a liquid phase is created that can flow to coat individual aggregate particles, bond them together, and fill in the voids. The liquid phase may also start to dissolve additional solid material. By reference to rates reasonably outside quenching dolimite, this liquid phase may partially crystallize without the need for the addition of nucleating additives because, due to partial melting, solid surfaces are already present to initiate crystallization. Mechanical pressure to compress material at temperature can help distribute the liquid phase between various solid surfaces and increase bonding. Vacuum to remove gas from voids can help to eliminate the resistance to void filling with the liquid phase.

Typically, the first components of the raw material to be liquefied are glass particles or feldspars, many of which select at temperatures of approximately 1,050 to 1,300 degrees C.

Preferably, the raw material comprises glass or feldspar which becomes seliquid at temperatures in the range of 1,100 to 1,200 degrees C. Cooling from these temperatures occurs at a temperature low enough to allow recrystallization to occur, preferably about 1 to 50 ° C. degrees C per minute, more preferably about 5 to 20 degrees C per minute, and most preferably about 10 degrees C per minute, when cooling begins from the peak temperature to the first hundred degrees of cooling. Cooling at a maximum speed of 10 degrees C per minute is also especially preferred as the material passes the temperature range of 600 to 500 degrees C to avoid fracture because of the associated volume change from beta to alpha phase transition of any quartz may be present in the material.

In the embodiments and examples of the following present invention, an amount of mine tailings, e.g. Historie Idaho-MarylandMine Tailings ("HDVIT") containing both individual rock fragments and demineral grains, are heated in a forming chamber to an optimal temperature, preferably in the range of 1,100 to 1,200 degrees C, and thereby partially fused over an ideal time period, preferably within 0.5 to 6 hours. During the partial melting process, the HIMT feedstock is simultaneously exposed to pressure modification, which is preferably the application of mechanical force to the material in the range of 1 to 200 psi (0.01 to 1.38 MPa), and which may additionally also be the application of vacuum to reduce the absolute pressure to the range of about 1 to 600 MB in order to remove interstitial gas phase.

Heating the depression-modified HIMT raw material results in a partially fused matrix which is then naturally cooled over an ideal time period. During the cooling period, freshly formed mineral crystallites with varying proportions of silicon, aluminum, iron, magnesium, calcium and sulfur crystallize from the molten starting material to form small crystallites distributed throughout the glass matrix. As previously stated, the invention does not employ crystallization catalysts or nucleating agents added to facilitate the crystallization process.

The newly formed crystallized minerals occurring in the glass matrix comprise a combination of grupopyroxene minerals, plagioclase feldspar group and sulfate group. The morphological characteristics of the newly crystallized minerals indicate their secondary growth from the molten part of the initial raw material, as opposed to forming a solid state glass reaction. Most notably, these secondary growth indicators include overall uniform size, crystalline morphology, and uniform composition of the newly formed mineral throughout the glass matrix.

In one embodiment, the invention provides a glassy non-porous impermeable polycrystalline composition comprising an amount of clasts, an amount of glass matrix, and an amount of at least one secondary crystalline phase. Said clasts comprise simple demineral grains, such as quartz, or rock fragments, or unfused glass fragments, or mineraloid grains. Said glass matrix is distributed between the clasts, binding to them and filling practically all interstitial space. Said at least one secondary crystalline phase is contained in the glass matrix, and comprises crystals formed from a molten mass with a mineral composition selected from the group consisting of ferromagnesian minerals, pyroxenes (e.g., clinopyroxene, orthopyroxene, augite, diopside, hyperstene, pigeonite, bronzite, enstatite), ilmanite, rutile, wollastonite, cordierite and anhydrite.

In one embodiment, the invention provides a method for processing mine tailings, resulting in a non-porous glassy impermeable polycrystalline composition. Said method comprises air drying a sample of mine tailings to less than 3% moisture; sort mine tailings to remove material larger than 516 microns; and calcine the mine tailings in the air at approximately 900 degrees C. The mine tailings are then mechanically compacted into a tube with an approximate pressure of 350 psi (2.41 MPa) at an approximate temperature of 1,130 degrees C for approximately 60 hours, and subsequently cooled at a rate of approximately 1 to 3 degrees C per minute, forming said decomposition comprising a clast phase, a glass phase, and at least one crystalline phase. Said clast phase comprises grains of simple minerals, such as quartz, or rock fragments. Said clast phase is distributed between said clast phase, binding to clast particles and practically filling the surrounding interstitial space. Said at least one crystalline phase is contained in said glass phase, and comprises crystals formed from a molten mass with a mineral composition consistent with minerals selected from the group consisting of bronzite, augite and pigeonite.

In another embodiment, the invention provides a method for processing mine tailings, resulting in a non-porous glassy impermeable polycrystalline composition. Said method comprises air drying a sample of mine tailings to less than 3% moisture; sort mine tailings to remove material larger than 516 microns; and calcine the mine tailings at approximately 900 degrees C. The mine tailings are then mechanically compacted into a tube with an approximate pressure of 300 psi (2.07 MPa) at an approximate temperature of 1,140 degrees C for approximately 6 hours, and subsequently cooled at a rate of approximately 10 to 20 degrees C / min, forming said decomposition comprising a clast phase, a glass phase and at least one crystalline phase. Said clast phase comprises grains of simple minerals, such as quartz, or rock fragments. Said glass phase is distributed between said clast phase, binding on the clast particles and filling approximately all the interstitial space around. Said at least one crystalline phase is contained in said glass phase and comprises crystals formed from a molten mass with a mineral composition consistent with selected minerals from the group consisting of bronzite, augite, pigeonite, anilite and eilmanite.

In another embodiment, the invention provides a method for processing mine mining metavolcanic rock resulting in a non-porous glassy impermeable polycrystalline composition. Said method comprises air drying a sample of the developing rock to less than 3% moisture; Sort the development rock into a 516 micron sieve. Development rock powder is then processed in the apparatus described in US Patent 6,547,550 (Guenther) at a temperature of approximately 1,160 degrees C, with mechanical pressure oscillating between approximately 30 psi and 160 psi (0.21 and 1.1 MPa) for a period of time. of time, in a partial vacuum atmosphere for approximately 60 minutes, subsequently resins at a rate of about 5 to 15 degrees C per minute, forming said composition comprising a clast phase, a glass phase and at least one crystalline phase. Said clastocyst phase comprises polyimineralic and monomineralic clasts. Said clast phase is distributed between said clast phase, linking the clast particles and filling practically all the interstitial space around it. Said at least one fasecrystalline is contained in said glass phase and comprises crystals formed from a molten mass with a mineral composition consistent with selected minerals from the group consisting of augite, pigeonite, magnemite and manilite.

In another embodiment, the invention provides a method for processing charcoal fly ash, resulting in a non-porous glassy impermeable polycrystalline composition. Said method comprises air drying a coal fly ash sample to less than 3% moisture; classify charcoal fly ash with a 516 micron sieve; and then burn the charcoal fly ash. The charcoal fly ash is then mechanically compacted at a pressure of approximately 300psi (2.07 MPa) in a pipe at a temperature of approximately 1,115 degrees C for approximately 10 hours, and subsequently cooled to an approximate speed of 10 to 20 degrees C per minute, forming said composition comprising a clast phase, a glass phase and at least one crystalline phase. Said clast phase comprises remaining clasts of the constituents of the initial feedstock. Said glass phase is distributed between said clast phase, binding to clast particles and filling approximately all the interstitial space around. Said at least one crystalline phase is contained in said clast phase and comprises crystals formed from a molten mass with a mineral composition consistent with selected minerals from the group consisting of wollastonite, plagioclase feldspar, anhydrite and calcium sulfate.

In another embodiment, the invention provides a method of processing waste materials selected from the group consisting of mine tailings, residual rock, quarry fines, slime, fly ash, debris ash, coal ash, incinerator ash, wood, and slag, resulting in a non-porous glassy waterproof polycrystalline composition. Said method comprises subjecting the waste materials to a sorting apparatus; transferring the waste materials from said rating apparatus to a heated rotary chamber for chemical transformation; transferring waste materials from said heated rotating chamber to a second heated chamber optionally fixed with a vacuum transferring waste materials from said second heated chamber to a third heated chamber positioned within a heating element applying pressure to the waste materials in said third heated chamber forming a hybrid rock; extruding said hybrid rock into a matrix device and removing said hybrid rock from said heated third chamber for subsequent use or modification.

The benefits, advantages and surprising discoveries of the present invention are, in short, remarkable. First and foremost, a surprising finding with respect to the applicant's invention is the presence of pyroxene inosilicates in the final composition and corresponding articles. Heretofore, pyroxene mineral compounds have not been detected in low-glassiness low-absorption synthetic rock materials such as those of the present invention of the applicant. Instead pyroxenes have been detected only conventionally in highly porous non-glassy materials. Also surprising is the fact that the resulting invention achieves maximum crystallization without the addition of crystallization catalysts or other nucleating agents. The raw material in the resulting invention is not heated beyond its melting point, but instead is only partially melted, which preserves crystallization core sites already present in the glass matrix. In contrast, conventional synthetic rock compositions have to employ crystallization catalysts to facilitate crystal formation by virtue of the corresponding raw materials being warmed above their melting point and completely fused into a homogeneous state during processing, which destroys potential crystallization sites. Conventional crystallization catalyst is required to provide a site for crystallization.

Also another surprising finding regarding the applicant's invention is that the glass matrix of the invention may comprise various amounts of glass, but that with less than approximately 20% glass the composition achieves impermeability. Conventional non-permeable or non-permeable synthetic rock materials require a high glass content to achieve impermeability.

The invention also has the advantage of providing compositions of matter comprising crystalline particles with a liquid glass-binding matrix, which allows the compositions to maintain a significant amount of high temperature plasticity other than tile / clay tile. With this level of protruding plasticity, the compositions may, while initially heated or reheated, be pressed, laminated or injected into other forms and a variety of useful products after initial preparation. For example, grain versions of solid compositions can be pressed into aggregates and round stones for a variety of construction uses, including for underlay, road base and paving stones. Alternatively, commonly known abrasives, such as silica carbide, roving quartz, may be added to the composition for subsequent use in sandblasting blocks and grinding wheels.

Another advantage of the present invention is that solids compositions and corresponding articles of manufacture are impermeable without the need for glazing. The impermeability of the invention is directly related to the fact that, unlike conventional synthetic rock materials, the composition and articles contain essentially zero open porosity, because of the continuous glass matrix structure that surrounds crystallites distributed throughout it. With the exception of certain rare cheap glassy clay products such as porcelain, conventional synthetic rock and ceramic products require glazing to achieve impermeability.

As noted previously, the applicant's invention contains virtually zero open porosity, which results in less porous and more impermeable articles compared to conventional ceramic materials. Surprisingly, voids (closed pores) can be induced in the applicant's invention to result in a lightweight construction type material without compromising the impervious characteristics of the invention.

Other aspects and preferred alternatives or embodiments of the invention exist. These will become apparent as the specification proceeds.

BRIEF DESCRIPTION OF DRAWINGS

Figure 1 is a micrograph obtained from non-commercially available ceramic tile scanning microscope analysis (Dal-Tile).

Figure 2 is a micrograph obtained by semi-commercially available electronically available ceramic tile / ceramic tile scanning (Balmor). Figure 3 is a micrograph obtained by semi-commercially available electronically available ceramic tile / ceramic tile scanning (Granitifiandre, Kashmir) White).

Figure 4 is a micrograph obtained by scanning electron probe analysis of an article of manufacture resulting from the applicant's tailings processing method, including an illustration of the article composition.

Figure 5 is a micrograph obtained by scanning electron probe analysis of an article of manufacture resulting from the applicant's tailings processing method, including an illustration of the article composition.

Figure 6 is a micrograph obtained by scanning electron probe analysis of an article of manufacture resulting from the applicant's method of processing mine rock, including an illustration of the composition of the article.

Figure 7 is a micrograph obtained by scanning electron probe analysis of an article of manufacture resulting from the applicant's fly ash processing method, including an illustration of the article composition.

Figure 8 is a schematic flowchart depicting an apparatus and method of processing waste mineral materials.

DETAILED DESCRIPTION OF THE INVENTION

First Modality

This embodiment is a mine tailing apparatus and process that employs a slow cooling scale, which results in the applicant's composition and corresponding manufacturing articles. Table 1. Composition of some of the feed materials <table> table see original document page 25 </column></row> <table>

EXAMPLE 1

A tailings sample from the Idaho-Marylan gold mine, with the overall composition shown in Table 1, was air dried to less than 3% moisture and graded to remove material larger than 516 microns (30mesh). The raw tailings material was air calcined at 900 degrees C. After calcification, the material, without additives, was mechanically compacted using a ram at a pressure of approximately 350 psi (2.41 MPa) in a bonded silicon carbide process tubing. nitride at a temperature of 1,130 degrees C for an extended period of time, approximately 60 hours at that temperature. The material was then slowly cooled to a rate of 1 to 3 degrees C per minute, forming a hybrid synthetic rock material, which was then removed from the process tube. The synthetic rock hybrid material specimens had an average rupture modulus of about 85 PMa (12,320 psi) and an average water absorption of about 0.3% determined by the ASTM C373 method. Other resulting data are shown in table 2.

Table 2. Physical Properties of Exemplary Synthetic Rock Hybrid Materials <table> table see original document page 26 </column> </row> <table>

Figure 4 is a backscattered electronic (BSE) image of the scanning electron probe of this IdahoMaryland mine tailings synthetic feedstock hybrid tailings material. Figure 4 illustrates the three typical characteristic phases of the unique mineralogical microstructure of this synthetic rock material. These phases include clasts (remnant primary grains partially dissolved from the tailings feedstock); a glass phase derived from partial melting of the primary mineral grains; and a secondary crystalline phase composed of similar sized crystallites occurring in the glass phase. The last secondary minerals crystallized from the liquid phase before cooling and formation of the glass phase. Figure 4 shows a remnant quartz-grain with round edges indicating dissolution of its previously angular grain contours (31). The practically complete fusion of most of the primary mineral constituents of the original feedstock components such as feldspar leaves little evidence of their existence in this synthetic rock without being a tinted area retaining the chemical signature of the original mineralogy (32).

The glass phase (33) with an aluminosilicate composition contains trace amounts of cations such as potassium, calcium, sodium, magnesium and iron (33). EDS micro-chemical analysis of glass in all ceramics indicates that the composition of the glass is heterogeneous and varies with respect to the aluminum: silicon ratio as well as the trace cation content (34).

The newly formed (secondary) crystallite comprises the fasecrystalline of this synthetic rock. The longer processing time resulted in secondary crystallites comprising 40-50% of the volume of this material. Crystallites appear in two recognizable morphologies, each with distinct chemical compositions determined by EDS. Some crystallites appear in reticulate and narrow skeleton forms and occur uniquely and in clusters (35). Crystallites of this morphology uniformly have a chemical composition mostly similar to the high magnesium pyroxene bronzite species, but low levels of eferral calcium (35). The size of the lattice-shaped crystallites ranges from 1 to 3 μιη in width and from 5 to 25 μπι in length.

The other common morphology of crystallites is a block-like shape that occurs similarly in a simple manner and slows (36). The latter morphology of crystallites is associated with calcium to iron reasons, similar to the high calcium but low iron depiroxene augite or pigeonite varieties. The size of these block crystals ranges from 4 to 15 μιη.

The continuous glass phase in this synthetic rock material left isolated isolates well spaced with little or no communication between them, resulting in very low absorption values (37).

Second Modality

This embodiment is a demine tailings processing method that employs a rapid cooling scale, which results in the applicant's composition and corresponding articles of manufacture.

EXAMPLE 2

A tailings sample from the Idaho-Maryland gold mine, with the overall composition shown in Table 1, was air dried to less than 3% humidity and graded to remove material larger than 516 microns (30mesh). The raw tailings material was air calcined at 900 degrees C. After calcification, the material, without additives, was mechanically compacted using a ram at a pressure of approximately 300 psi (20.7 MPa) in a bonded silicon carbide process tubing. with nitride at a temperature of 1,140 degrees C with a residence time of approximately 6 hours at temperature. The material was then extruded into a rectangular die (15.2 by 1.3 cm) with a top face length of 3.5 cm, subsequently cooled at a rate of about 10 to 20 degrees C per minute, forming a material. synthetic rock hybrid. The bodies of proven resulting synthetic rock hybrid material had an average burst modulus of about 42 MPa (6,060 psi) and an average water absorption of about 3.2% determined by the ASTM C373 method. Other data are shown in table 2.

Figure 5 shows the backscattered electronic image (BSE) of the scanning electron probe of the synthetic rock hybrid material resulting. Figure 5 illustrates the three typical characteristic phases of the unique mineralogical microstructure of this synthetic rock material. These phases include clasts (remnant primary grains partially dissolved from the tailings feedstock); a glass phase derived from partial melting of the primary mineral grains; and a secondary crystalline phase composed of similarly sized crystallites enveloped in the glass phase. The last secondary minerals crystallized from the liquid phase during cooling, probably before the formation of the glass phase. Figure 5 shows a remnant primary quartz grain with round edges indicating dissolution of its initially angular grain contours (41).

The nearly complete fusion of most of the primary mineral constituents of the original feedstock components leaves little evidence of their existence in this synthetic rock.

The glass phase (42) with an aluminosilicate composition contains trace amounts of cations such as potassium, calcium, sodium, magnesium and iron (42). EDS microchemical analysis of glass through ceramics indicates that the glass composition is heterogeneous and varies with respect to aluminum: silicon ratio as well as trace cation content (43).

Four newly formed secondary crystalline phases are apparent in this synthetic rock material including two types of pyroxenodistincts, anhydrite and ilmanite. Pyroxene crystallites appear in two morphologies, each with distinct chemical compositions, determined by EDs. A morphology of pyroxene crystallite is a form of reticular reticulate (44). Cross-linked pyroxenes uniformly have a chemical composition more similar to bronzite species with high magnesium but low calcium and iron (44). Crystallite sizes range from 1.5 to 3 μπι in width and from 5 to 50 μιτι in length. The shorter processing time to produce this material (compared to example 1) prevented the development of complex crystallite clusters. Other pyroxene crystallites occur with an equating typobloc morphology (45). This last type of pyroxene occurs simply or in simple groupings. The latter morphology of pyroxene crystallites is associated with calcium to iron ratios similar to augitaou or pigeonite varieties with high calcium but low iron content. Block type crystallites range from 1 to 5 μηι.

Sulfur in this synthetic rock combined with calcium to form clumps of anhydrite crystallites (46). Individual crystallites in the clusters range from 2 to 7 μιτι in size.

Small crystallites of similar dimensions of 1 to 5 μιτι ilmanite (iron oxide and titanium) appear randomly arranged in the vitreous matrix (47).

The continuous glass phase in this synthetic rock material left little voids, and widely spaced isolates (48) with little or no communication between them, resulting in very low absorption values.

Third Mode

This embodiment is a method of processing the metavolcanic mine rock that employs a rapid cooling program, which results in the applicant's composition and corresponding articles of manufacture.

EXAMPLE 3

A composite core drilling sample taken from the metavolcanic rock (andesite, dacite, diabase and others) from the Idaho-Marylan mine ("development rock") was air dried to less than 3% moisture, and ground to a fine size. enough to pass 100% in a 516 micron (30 mesh) screen. The developmental rock powder had a composition shown in Table 1. The developmental rock powder, without additives, was processed in an apparatus described in US 6,547,550 (Guenther) at a temperature of 1,160 degrees C, with a mechanical pressure oscillating between about 160 psi and 30 psi (1.1 to 0.21MPa) with a 10 minute oscillation period, in a partial vacuum atmosphere (about 170 mbar absolute pressure), with a dwell time of about 60 minutes before consolidated extrusion of the hybrid synthetic rock buffer. After extrusion, the buffer was cooled to a rate of about 5 to 15 degrees C per minute. The bodies of the resulting proven synthetic rock hybrid material had an average burst modulus of about 64 MPa (9,280 psi) and an average water absorption of about 0.8% determined by the ASTM C373 method. Other resulting data are shown in table 2.

Figure 6 is the backscattered electronic image (BSE) of the electronic scanning probe of the synthetic rock material resulting from the Idaho Maryland developmental rock feed load. Figure 6 illustrates the three characteristic phases typical of the unique mineral microstructure of this synthetic rock material that collectively comprise an aggregate arrangement (or loophole). These three phases include the remaining partially dissolved primary grains of the original metavulcan feedstock constituents; a glass phase derived from partial melting of the primary mineral grains; and secondary crystalline phases composed of similar sized crystallites enveloped in the glass phase. The last secondary minerals crystallized from the liquid phase during cooling, probably before the formation of the glass phase. Figure 6 shows numerous remnant grains of a variety of primary constituents forming a relatively coarse fraction of clasts. These primary lytic grains include polyvinyl metavulcanic rock fragments (51) and monomineralic mineral grains (52). Specific minerals occurring in both monomeric grains composed of a single mineral and multi-mineral composite polyimineral rock fragments include plagioclase feldspar (53); pyroxene (54); and the remains of degraded chlorite (55). Other primary minerals inherited from feedstuff constituents that also occur, although not illustrated in Figure 6, include spheno, quartz and hematite.

The partial fusion of feldspar (53) that occurs at the metavulcan feed charge contributes to the formation of a molten phase that created a glass matrix upon cooling (56). Round feldspar grain margins indicate dissolution or fusion of their initially angular grain contours. The glass phase 56 with a dealuminosilicate composition contains trace amounts of cations such as potassium, calcium, sodium, magnesium and iron. EDS micro-chemical analysis of glass throughout ceramics indicates that the glass composition is heterogeneous and varies with respect to aluminum: silicon ratio as well as trace cation content (57).

Figure 6 illustrates the formation of the secondary crystalline phase which crystallized from the liquid phase. Pyroxene crystallite clusters appear at various locations enveloped by the glass phase (58). The individual depiroxene crystallites in the clusters have a block-like morphology with calcium to iron ratios similar to the augite epigeonite varieties. Other secondary minerals that crystallized from faseliquid but not shown in figure 6 include magemite (spinel group) and ilmanite (iron oxide and titanium).

The continuous glass phase of this synthetic rock material envelops virtually the entire grain margin of the clasts, resulting in well-spaced isolated voids (59). There is little or no communication between isolated voids, resulting in very low absorption values determined for this synthetic rock hybrid material.

The unique structural attribute of this synthetic rock material is the aggregate gap mineralogical microstructure created by the three important components which includes: 1) the remaining primary clasts, 2) the glass phase, and 3) the secondary crystallite phase. This structural arrangement of aggregate component (or constituent) gaps creates an aggregate mineralogical forthemostructure with superior strength and durability properties unique to this synthetic rock material.

Fourth Modality

This embodiment is a method of processing flywheel ash using an accelerated cooling scale, which results in the applicant's composition and corresponding articles of manufacture.

EXAMPLE 4

Coal fly ash material was obtained from a coal power plant, specifically Valmy Train 2 in Winnemucca, NV. Composition of the raw material is shown in table 1. The material was air dried to less than 3% humidity, and rated to pass 100% in a 516 micron (30 mesh) screen. After calcination, the additive-free calcined charcoal hull material was mechanically compacted using a ram at a pressure of approximately 300 psi (2.07 MPa) in a nitride-bonded silicon carbide process tube at a temperature of 1,115 degrees C residence time of approximately 10 hours at temperature. The material was then extruded into a cylindrical die, and subsequently cooled at a rate of about 10 to 20 degrees C per minute, forming a hybrid synthetic rock material. Specimens of the resulting hybrid synthetic rock material had an average rupture modulus of about 57 MPa (8,230 psi) and an average water absorption of about 0.7% as determined by the ASTMC373 method. Other resulting data are shown in table 2.

Figure 7 is a backscattered electronic image (BSE) of the scanning electron probe of the synthetic rock material fabricated from the feedstock of fly ash ash. Figure 7 illustrates the three typical characteristic phases of the unique microstructure of this material. synthetic rock that collectively-comprises an aggregate structural arrangement. These three phases include remaining partially dissolved primary grain clasts of the original fly ash feedstock constituents15; a glass phase derived from partial melting of the primary mineral grains and fly ash; and secondary crystalline phases composed of similar sized crystallites enveloped in the glass phase. The latter secondary minerals crystallized from the faseliquid during cooling, probably before the formation of the glass phase. Figure 7 shows remnant grains of primary constituents remaining in this synthetic rock, including quartz (61) and fly ash glass beads (62).

The partial fusion of fly ash glass beads - the dominant constituent of the feedstock - created a fused phase that formed a continuous glass matrix upon cooling (63). Fasevidro (63) with an aluminosilicate composition contains amounts of cations such as potassium, calcium, sodium, magnesium and iron. EDS analysis of glass across ceramics indicates that the glass composition is heterogeneous and varies with respect to the aluminum: silicon ratio as well as the trace cation content (64).

Figure 7 illustrates the formation of up to four secondary crystalline phases that crystallized from the liquid phase during the cooling process. These secondary crystalline phases include: wollastonite decrystallite clusters (65), some of which nuclearize into the remaining primary quartz grains (61); deformed plagioclase feldspar crystallites (66) and pyroxene (67) randomly distributed in fasevidro; and block type anhydrite (calcium sulfate) crystallites not shown in Figure 7. The anhydrite phase is a major component of this synthetic rock material and serves as a primary receptacle for sulfur which was a dominant constituent of the fly ash ash residual material.

Individual wollastonite crystallites range in size from 1 to 6 μιη. Reticulated plagioclase crystallites and pyroxene range from 1 to 5 μιη in width and 2 to 15 μπι in length. The largest block-type anhydrite phenocrystals have a size that can be resolved by polarized light microscopy, with typical sizes ranging from 10 to 70 μηι.

The continuous glass phase of this synthetic rock material covers the entire grain portion of the primary and secondary mineral grains, resulting in little or no void (68). The predominant void space in this synthetic rock was inherited and associated with primary fly ash beads (69). There is little or no communication between any of the isolated voids resulting from the very low absorption values determined for this synthetic rock material.

The unique structural attribute of this synthetic rock material is the aggregate loophole microstructure created by the three important components which includes: 1) the remaining primary clasts, which in this example include mineral grains and mineraloid grains such as fly ash beads, 2) the glass phase, and 3) the secondary crystallite phase. The development of large crystallized wollastonite crystallite clusters around primary quartz grains contributes to the coarse deagregated fraction (65). This decomposing (or constituent) aggregate gap structural arrangement creates a strong aggregated mineralogical microstructure with superior strength and durability properties unique to this synthetic rock material.

Fifth Modality

This embodiment is a method of processing residual mineral materials, such as mine tailings, ash, slag, and similar sludge, which results in the applicant's corresponding composition and articles of manufacture.

Referring to FIG. 8, the raw material for the manufacture of synthetic hybrid swab 100 may be, for example, mine tailings, rocharesiduals, quarry fines, slime, fly ash, charcoal ash, incinerator ash, or mixtures. such materials together or as pure ceramic feed materials, such as clay, feldspar, quartz, talc and the like. Silicate waste materials are particularly well suited for use as raw materials. Raw material 100 is distributed to the rating apparatus 120, which has an outlet for larger particle size 122 larger than a predetermined sieve opening size, and which additionally has an outlet 123 for smaller particle size 124, smaller than a predetermined sieve aperture size. Larger particles 122 may be recycled to the grading apparatus 120 by a shredding process (not shown), or thrown away.

Smaller raw material particles 124 are transferred to a hopper 131 of rotary calcination 130. The feed auger 137 is driven, for example, by motor 136, and particulate matter is then carried to a heated rotary cylinder 132. Cylinder132 is heated by any of several means, including, but not limited to, electrical resistance heaters, gas burners, and our exhausted heat from other processes. The drive 138 rotates the cylinder 132, which may have a smooth inner surface, or alternatively may have a surface that is corrugated or otherwise roughened, for example, with projections, to provide a means for the material to be repeatedly raised and released as that he moves through the cylinder. Cylinder 132 is inclined to a shallow horizontal angle to slowly drive the powder toward discharge assembly 133. Calcination 130 has optionally gas inlet 135 for adding air or other gases and releasing air 134 for product removal. combustion products or other decomposition products. Calcination 130 is operated at temperatures below the point at which the material begins to soften and synthesize, but at elevated temperatures such that the material is preheated and dried. Other useful chemical transformations may be performed in calcination, including, but not limited to, combustion of organic materials, conversion of hydrated minerals to dehydrated oxides, desulphurization, carbonate decomposition and the like. The process temperature for each of these operations varies but is generally range 100 to 1,000 degrees C.

The calcined particulate material 139 exits at a temperature in this range, preferably about 800 to 1,000 degrees Celsius, and passes valve 140 to hopper 150. Valve 140 can be closed to provide a hermetic vacuum seal between hopper 150 and calcination130. Preferably, valve 140 is a high temperature rotary valve that can continuously flow material through it while still maintaining a pressure differential.

Hopper 150 is preferably thermally insulated, or alternatively provided with a heat source to maintain particulate material temperature. Vacuum outlet 151 may be provided for connection to vacuum 152. Vacuum removes trapped and interstitial gas from particulate material and contributes to the production of synthetic hybrid rock material in voids of a subsequent extrusion step. Vacuum may also reduce the oxidation of minerals and may increase the variety or level of crystallization in the resulting product.

Flange opening 161 of hopper 150 is connected to feed 160 at flange opening 161. Feed 160 can function as an alternating-action ram, or with an auger, or both. Endless 162 is rotated by shaft 163 and drive 164, thus taking particulate synthetic hybrid rock material directly to the extruder cylinder 180. The entire auger / drive assembly can be moved axially, for example by means of hydraulic ram 165, moving axially on the hydraulic cylinder 166 because of the pressure created by the pump or hydraulic power unit 167. The axial movement of the worm 162 also transfers particulate material to the extruder cylinder 180.

A typical operating cycle for using both the end and ram aspects of the invention together is as follows. With little or no force, perhaps a force behind hydraulic ram 165, drive 164 rotates worm 162, which transfers particulate material to extruder cylinder 180. When available space in extruder cylinder 180 is filled with newly transferred particulate material , the drive 164 is deactivated, and the worm 162 stops spinning. The ram 165 is then energized by the power unit 167 to provide an endless axial force 162, which in turn pushes the material into the extruder cylinder 180. Material is transferred axially down into the extruder cylinder 180 in this manner by a predetermined distance. Once the predetermined distance has been reached, the force applied by the water hammer is reduced, and the cycle can be repeated.

The extruder cylinder 180 can be constructed of material with excellent high temperature resistance, good thermal conductivity, acceptable strength and excellent resistance to wetting or reacting with materials to be processed in the extruder. Preferably, the extruder cylinder 180 is constructed of silicon carbide (SiC). Most preferably, the extruder cylinder 180 is constructed of nitride-bonded desilicon carbide (SiN-SiC), for example Advancer ™ material available from St. Gobain Industrial Ceramics.

Extruder cylinder 180 is compressed between feed 160 and crosshead 190 and supported within furnace 170. Furnace 170 provides heat, for example by electric resistance heaters or gas combustion, and is preferably a split tube design for ease of maintenance. It also preferably has multiple temperature control zones along its length. The furnace 170 provides heat to raise the temperature of the extruder cylinder 180 sufficiently to melt, sinter, partially melt or otherwise obtain the desired glazing material within it.

Within the extruder cylinder 180, feed-fed particulate material 160 is transferred axially toward the reducing die 181 and heated, thereby consolidating and vitrifying the particulate material into at least partially fused synthetic hybrid rock material.

The reducing die 181 attached to the cylinder end of the extruder 180 provides a flow resistance of said at least partially fused synthetic hybrid rock material and thus increases the required pressure applied by battering ram 165 to transfer the material, providing a mechanism for material consolidation. The optional high-sided die182 connected to the end of the reducing die 180 can further increase flow resistance. In the absence of the high-face die 182, a spacer may be used, for example, an additional short length of the cylinder, similar to the extruder cylinder 180. At the discharge end of the extruder, ie where the high-face die or spacer exits From furnace 170, an insulating ring 183 made of thermally insulating resistant material, preferably zirconia, is placed. The insulating ring 183 minimizes heat conduction from the furnace to crosshead 190, and is captured in a lowered opening within crosshead 190.

Crosshead 190 is a rigid plate allowing the passage of extruded synthetic hybrid rock product 130 through a hole in the center, further providing mechanical compression to the insulating ring 183, high-sided die 182, reducing die 181 and extruder cylinder 180. the crosshead 190 is supported by a plurality of rigid springs 191, each reacting to a load cell 192 mounted on a fixed rigid support.

The extruded synthetic hybrid rock product 130 exits the high-sided die 182, passes through the insulating ring 183 and crosshead 190, and is supported and transferred by a plurality of rollers 201 within the heated chambers200 and 220. the temperature in the heated chambers 200 and 220 is maintained. such that the extruded synthetic hybrid rock material 230 remains sturdy enough to be cut by the scissors 210 attached to the tattooers 212. After cutting, the extruded synthetic hybrid rock material 220 can be removed from the heated chamber 220 and resined by various means to provide useful products. . Alternatively, the extruded synthetic hybrid rock material 230 can be transferred to subsequent operations such as press, forming, rolling, high temperature nitrification molding, thereby efficiently using heat in the material.

Claims (78)

Composition, characterized in that it comprises, in combination, a molten mixture having: a clast phase, a glass phase; at least one crystalline phase, wherein said at least one crystalline phase comprises newly formed crystallites dispersed in said glass phase. Composition according to Claim 1, characterized in that said at least one crystalline phase comprises crystallites which have chemical compositions consistent with elements of the following mineral groups: pyroxene, plagioclase feldspar, wollastonite or mineral group sulfates. Composition according to Claim 1, characterized in that said at least one crystalline phase comprises crystallites which have concentrations of calcium, magnesium and iron consistent with chemical compositions that particularize the demineral pyroxene group elements. Composition according to Claim 1, characterized in that said at least one crystalline phase comprises crystallites which have chemical composition consistent with elements of the piroxenode mineral group which have the chemical composition (Mg, Fe MSiiO6]. Composition according to Claim 1, characterized in that said at least one crystalline phase comprises crystallites which have chemical composition consistent with elements of the piroxenode mineral group which have the chemical composition (Ca, Na, Mg, Fe2 +, Mn, Fe3 + , Al, Ti) 2 [(Si, Al) 206]. Composition according to Claim 1, characterized in that said at least one crystalline phase comprises crystallites which have chemical composition consistent with elements of the piroxenode mineral group which have the chemical composition (Mg, Fe2 + Ca) (mg, Fe2 +). [Si206]. Composition according to Claim 1, characterized in that said at least one crystalline phase comprises crystallites which have chemical composition consistent with elements of the piroxenode mineral group which have the chemical composition Ca (Mg, Fe) [SiC> 6]. Composition according to Claim 1, characterized in that said at least one crystalline phase comprises anhydrous CaSO4. Composition according to Claim 1, characterized in that said at least one crystalline phase comprises crystallites which have slatted morphological characteristics consistent with pyroxene mineral group elements. Composition according to Claim 1, characterized in that said at least one crystalline phase comprises crystallites having massive morphological characteristics consistent with elements of the pyroxene group of minerals. Composition according to Claim 1, characterized in that said at least one crystalline phase comprises crystallites which occur either alone or in clusters. Composition according to Claim 1, characterized in that said glass phase is heterogeneous and comprises aluminum, silicon and lower concentrations of cations. Composition according to Claim 1, characterized in that said clast phase is partially dissolved and comprises remaining primary clasts derived from the original feedstock constituents; and wherein said at least one crystalline phase comprises newly formed secondary crystallites of a molten mass. Composition according to Claim 1, characterized in that said at least one crystalline phase comprises crystallites having chemical composition consistent with the pyroxene group elements of minerals having the chemical compositions (MgjFe2 + MSi2O6] and (CajNa, Mg, Fe2 + Mn, Fe3 +, Al, Ti) 2 [(Si5 Al) 2 O6]. Composition according to Claim 14, characterized in that said clast phase is partially dissolved and comprises remaining primary grains derived from the original feedstock constituents; and wherein said at least one crystalline phase comprises newly formed secondary crystallites of a molten mass. 16. Composition, characterized in that it comprises, in combination, a molten mixture having: a clast phase, a heterogeneous glass phase comprising aluminum, silicon smaller cation equivalents; a plurality of newly formed crystalline phases, wherein said plurality of newly formed crystalline phases is dispersed in said glass phase and comprises crystallites which have a chemical composition consistent with the pyroxene mineral group elements having chemical compositions (Mg5Fe) 2 [Si2O6 ], (Ca, Na5Mg5Fe2 + 5Mn, Fe3 +, Al, Ti) 2 [(Si, Al) 206], (CaSO4) and (FeTiO3). Composition according to Claim 16, characterized in that said clast phase is partially dissolved comprises remaining primary clasts derived from the original feedstock constituents; and wherein said plurality of newly formed crystalline phases comprises newly formed secondary crystallites of a molten mass. 18. Composition, characterized in that it comprises, in combination, a molten mixture having: a clast phase, a heterogeneous glass phase comprising aluminum, silicon smaller cation equivalents; a plurality of newly formed crystalline phases, wherein said plurality of newly formed crystalline phases is dispersed in said glass phase and comprises crystallites having constituent concentrations consistent with the elements of the pyroxene group of minerals having the chemical compositions (Mg5Fe XtSi2O6], (Mg, Fe2 +) (Mg, Fe2 + XSi2O6], (CaSO4) and (FeTiO3). Composition according to Claim 18, characterized in that said clast phase is partially dissolved and comprises remaining primary clasts derived from the original feedstock constituents, wherein said plurality of newly formed crystalline phases comprises newly formed secondary crystallites. of a molten mass. 20. Composition, characterized in that it comprises, in combination, a molten mixture having: remaining clasts, a glass phase; a plurality of newly formed crystalline phases, wherein said plurality of newly formed crystalline phases comprises crystallites dispersed in said glass phase. Composition according to Claim 20, characterized in that said remaining clasts are monomineralic and polyimineral. Composition according to Claim 20, characterized in that said remaining clasts comprise the plagioclase feldspar, pyroxene and degraded chloride osminerals. Composition according to Claim 20, characterized in that said glass phase is heterogeneous and comprises aluminum, silicon and smaller amounts of cations. Composition according to Claim 23, characterized in that said cations comprise, in combination, potassium, calcium, sodium, magnesium and iron. Composition according to Claim 20, characterized in that said plurality of newly formed crystalline phases comprises crystallites having chemical composition consistent with elements of the pyroxene group of minerals with the chemical compositions (Ca, Na, Mg, Fe2 +, Mn, Fe3 +, Al, Ti) 2 [(Si, Al) 206] and (Mg, Fe2 + Ca) (Mg, Fe2 +) [Si2O6]. Composition according to Claim 20, characterized in that said plurality of newly formed crystalline phases comprises crystallites which have massive morphological characteristics with a chemical composition consistent with mineral group pyroxene elements with the chemical compositions (Ca, Na, Mg, Fe2 +, Mto5 Fe3 +, Al, Ti) 2 [(Si, Al) 206] and (Mg, Fe2 + Ca) (Mg, Fe2 +) [Si206). 27. Composition, characterized in that it comprises, in combination, a molten mixture having: grains of quartz and ash remaining mineraloid and mineral, a glass phase; a plurality of newly formed crystalline phases, wherein said plurality of newly formed crystalline phases comprises crystallites dispersed in said glass phase. Composition according to Claim 27, characterized in that said glass phase is heterogeneous and comprises, in combination, aluminum, silicon and smaller amounts of cations. Composition according to Claim 27, characterized in that said plurality of newly formed crystalline phases comprises crystallites with chemical composition consistent with chemical composition (CafSiOa]). Composition according to Claim 27, characterized in that said plurality of newly formed crystalline phases comprises slatted plagioclase feldspar crystallites. Composition according to Claim 27, characterized in that said plurality of newly formed crystalline phases comprises pyroxene crystallites. Composition according to Claim 27, characterized in that said plurality of newly formed crystalline phases comprises crystallites having the chemical composition (CaSC> 4). 33. Composition, characterized in that it comprises, in combination, a molten mixture having: remaining mineral and grains of quartz and gray, a glass phase; a plurality of newly formed crystalline phases, wherein said plurality of newly formed crystalline phases comprises crystallites having a chemical composition (CafSiOs]), slatted plagioclase feldspar crystallites, pyroxene crystallites having the chemical composition ( CaSO4). 34. Hybrid rock, characterized by the fact that it is formed by the process of: recycling waste material selected from the group consisting of mine refills, fly ash, debris ash, slag, fine stone, or slime; exubmit the pressure waste materials; heat the waste materials, whereby the waste materials convert to a hybrid rock with a water absorption characteristic of less than 7%. Hybrid rock according to claim 34, characterized in that said hybrid rock has water absorption of less than 4%. Hybrid rock according to claim 34, characterized in that said hybrid rock has water absorption of less than 1%. Hybrid rock according to claim 34, characterized in that said hybrid rock has a water absorption of less than 0.5%. Hybrid rock according to claim 34, characterized in that the waste material is distributed to a grading apparatus to separate smaller and larger sized waste particles from the mine tailings to be processed. Hybrid rock according to claim 38, characterized in that, after classification, the waste material is transferred to a heated rotating chamber. Hybrid rock according to claim 39, characterized in that the residual material in said heated rotating chamber undergoes chemical transformation. Hybrid rock according to claim 40, characterized in that said chemical transformation of the waste material comprises drying, preheating, combustion, dehydration, desulphurization, decomposition and the like. Hybrid rock according to claim 40, characterized in that the waste material exits said heated rotating chamber and passes through a valve before entering a second heated chamber. Hybrid rock according to claim 42, characterized in that said valve is rotatable and capable of continuously passing through the waste material while maintaining a pressure gradient. Hybrid rock according to claim 42, characterized in that a vacuum is applied to the heated second chamber nadite residual material. Hybrid rock according to claim 42, characterized in that the waste material exits said second heated chamber and is then transferred to a third heated chamber positioned within a heating element. Hybrid rock according to claim 45, characterized in that pressure is applied to the waste material in the third heated chamber for a predetermined period of time. Hybrid rock according to claim 46, characterized in that said hybrid rock passes through a matrix device and is removed from said third heated chamber for subsequent use, or alternatively directed to further heated terminal chambers for further coding. 48. A process for converting waste material into a hybrid rock, wherein the waste material is selected from the group consisting of mine tailings, fly ash, slag ash, slag, quarry fines, or sludge, characterized in that the absorption of water is less than 7%, the steps including: pressurizing the mine tailings, heating the mine tailings; make a useful yet deformable article of manufacture. Process according to claim 48, characterized in that the waste material is heated and pressurized within a chamber heated to an optimized temperature with an optimized amount of pressure for an optimized period of time. A process according to claim 49, characterized in that the waste material is heated and pressurized within the dictate chamber heated to a temperature of approximately 1,130 degrees C for a period of approximately 60 hours. Process according to claim 49, characterized in that during heating the waste material is pressurized to a pressure of approximately 350 psi (2.41 MPa). Process according to claim 49, characterized in that the waste material is cooled at a rate of approximately 1 to 3 degrees per minute. A process according to claim 49, characterized in that the waste material is heated and pressurized within the dictate chamber heated to a temperature of approximately 1,140 degrees C for a period of approximately 6 hours. Process according to claim 53, characterized in that during heating the waste material is pressurized to a pressure of approximately 300 psi (2.07 MPa). Process according to Claim 53, characterized in that the waste material is cooled at a rate of approximately 10 to 20 degrees per minute. A process according to claim 49, characterized in that the waste material is heated and pressurized within the dictate chamber heated to a temperature of approximately 1,160 degrees C for a period of approximately 60 minutes. Process according to Claim 56, characterized in that during heating the waste material is pressurized to an oscillating pressure between approximately 30 psi and 160 psi (0.21 MPa and -1.1 MPa). Process according to claim 56, characterized in that the waste material is cooled at a rate of approximately 5 to 15 degrees C per minute. A process according to claim 57, characterized in that the waste material is subjected to said oscillating pressure in a partial vacuum environment. A process according to claim 49, characterized in that the waste material is heated and pressurized within the dictate chamber heated to a temperature of approximately 1,115 degrees C for a period of approximately 10 hours. Process according to claim 60, characterized in that during heating the waste material is pressurized to a pressure of approximately 300 psi (2.07 MPa). Process according to claim 60, characterized in that the waste material is cooled at a rate of approximately 10 to 20 degrees C per minute. A process according to claim 49, characterized in that said hybrid rock is extruded into a die to consolidate said hybrid rock, thereby forming a useful article of manufacture. 64. Hybrid rock, characterized by the fact that its primary constituent component of mine tailings is modified to present less water absorption due to the glass matrix in which the crystallites are distributed. 65. Hybrid rock, characterized by the fact that its primary constituent component of mine tailings, or silicate waste materials, is selected from the group consisting of mine rock, fly ash, slag ash, slag, quarry fines or slime; said hybrid rock being formed by recycling tailings from mine or silicate waste materials, and subjecting waste materials from silicate waste to pressure, and subjecting waste materials from silicate waste to heat, so as to have low water absorption. 66. Hybrid rock, characterized in that it comprises a partially dissolved granular phase comprising, in combination: remaining mine tailings, a glass phase; a crystalline phase distributed in said glass phase, whereby said hybrid rock has low water absorption. 67. Hybrid rock, characterized by the fact that its constituent component of mine tailings or silicate waste materials is selected from the group consisting of mine rock, chisel, debris ash, slag, quarry fines or slime; ; at least one crystalline phase distributed in said glass phase, said hybrid rock being formed by the recirculation of mine tailings or silicate waste materials, and subjecting mine tailings or silicate waste materials to pressure, and subjecting mine tailings or waste materials of heat silicate, to present low water absorption. 68. A hybrid rock forming apparatus, characterized in that it comprises, in combination: a device for preheating selected silicate waste materials from the group consisting of mine tailings, mining rock, fly ash, debris ash, slag, quarry fines, or slime; a device for feeding silicate waste materials to a heated chamber; a device for heating said heated chamber; and a device for dispensing hybrid plastic rock from an output of the heated dictachamber. An apparatus according to claim 68, characterized in that said device for preheating desilicate waste materials comprises a heated rotary chamber maintained at an ideal temperature for preheating and drying the silicate waste materials without melting the silicate waste materials. . Apparatus according to claim 69, characterized in that said heated rotating chamber is at an optimum angle to facilitate the conduction of the silicate waste materials towards a discharge assembly. Apparatus according to claim 69, characterized in that said heated rotary chamber is optionally fixed with a gas inlet and vent for the respective inlet and removal of air, similar gases. Apparatus according to claim 69, characterized in that said ideal temperature of said heated rotary chamber is approximately 800 to 1,000 degrees C. Apparatus according to claim 68, characterized in that said device for feeding desilicate waste materials into said heated chamber comprises an axial or rotational force doubled capacity press. Apparatus according to claim 73, characterized in that said press assembly is driven by hydraulic force. Apparatus according to claim 68, characterized in that said device for heating said heated chamber comprises mounting said heated chamber on a heating element which substantially surrounds said heated chamber. Apparatus according to claim 75, characterized in that said heating element comprises a split tube design and is constructed with multiple temperature zones all around it. Apparatus according to claim 75, characterized in that said heating element provides heat by means of electrical resistance heaters, gas combustion and the like. Apparatus according to claim 68, characterized in that said device for distributing hybrid plastic rock from an outlet of said heated chamber comprises a pressure resisting device for consolidating said hybrid plastic rock material; and a die device with an opening that allows said hybrid plastic swab material to pass therethrough.